KR102846552B1 - Stator assey and motor consisting of stator assey - Google Patents

Abstract

The present invention relates to a stator assembly and a motor including the stator assembly, the motor including a cylindrical yoke including a soft magnetic material, a plurality of teeth extending in the direction of the central axis of the yoke, a shoe provided at the end of the teeth in the direction of the central axis of the yoke, a coil slot provided between the plurality of teeth and being a space formed by adjacent teeth, and a coil module including a plurality of coils accommodated in the coil slot, wherein the coil slot includes first and second regions that are distinct from each other, and the maximum width of the first region is wider than the maximum width of the second region.

Description

{STATOR ASSEY AND MOTOR CONSISTING OF STATOR ASSEY}

The present invention relates to a stator assay and a motor including the stator assay, and more particularly, to a stator assay and a motor including the stator assay that can prevent damage to an insulator attached to a coil when inserting the coil into the stator.

Recently, research is being actively conducted to reduce the defect rate in the motor manufacturing process.

Typically, a conventional hairpin coil motor is largely composed of a rotor, a stator, and a plurality of coils having a “U” shape and each coil having an insulator on both sides of the “U” shape, which are accommodated in coil slots of the stator.

Here, a process for manufacturing a stator of a conventional hairpin coil motor is examined. Insulating paper is inserted as an insulator into a rectangular coil slot provided in the stator of the hairpin coil motor so that a coil can be accommodated, and then the coil is inserted between the insulating papers, or the coil with the insulator attached is inserted into the rectangular coil slot provided in the stator.

In addition, the process of inserting coils into coil slots is repeated several times so that multiple coils can be inserted into the coil slots in a stacked manner, and then the ends of each coil are joined to form one coil.

In this way, it becomes possible to manufacture a high-efficiency motor with an increased coil space factor through a hairpin coil motor.

However, in the case of a conventional hairpin coil motor, when a coil with an insulator attached is inserted into a rectangular coil slot, the insulator may be damaged by colliding with the stator teeth or yoke.

In this way, if the insulation is damaged, the insulation between the coil and the stator, or between the coils, may be destroyed, which may cause defects in the motor manufactured through this, which may lead to an increase in the defect rate in the process and subsequent cost consumption.

Korean Patent Publication No. 10-2013-0052834 (“Stator structure of a coil-wound motor and its manufacturing method,” published on May 23, 2013)

The present invention has been devised to solve the above problems, and a motor including a stator assay and a stator assay according to the present invention is characterized in that a coil slot for accommodating a coil of a stator is divided into a first region and a second region, and a maximum width of the first region is wider than a maximum width of the second region, thereby providing a stator assay and a motor including a stator assay that can produce a motor with a low defect rate by safely inserting the hairpin coil into the coil slot without damaging the insulation of the hairpin coil.

In order to solve the above problem, a stator assembly according to one embodiment of the present invention is cylindrical, and includes a yoke including a soft magnetic material, a plurality of teeth extending in the direction of the central axis of the yoke, a shoe provided at the end of the teeth in the direction of the central axis of the yoke, a coil slot provided between the plurality of teeth and being a space formed by adjacent teeth, and a coil module including a plurality of coils accommodated in the coil slot, wherein the coil slot includes first and second regions that are distinct from each other, and the maximum width of the first region is wider than the maximum width of the second region.

Additionally, the first region is characterized in that it is provided in a region further from the central axis of the yoke than the second region.

Additionally, the maximum width of the first region is characterized by being equal to or greater than 1.05 times and less than 1.25 times the maximum width of the second region.

Additionally, the maximum width of the first region is characterized by being equal to or greater than 1.4 times and less than 1.6 times the width of the coil.

Additionally, the maximum width of the second region is characterized by being equal to or greater than 1.2 times the width of the coil and smaller than the maximum width of the first region.

Additionally, the length of the first region is characterized by being shorter than the length of the second region.

In addition, when the thicknesses (B) of the plurality of coils included in the coil module are all the same, and the number of coils in which at least some of the plurality of coils are accommodated in the first region is N, the length (L1) of the first region is characterized by satisfying the following equation 1.

(Formula 1) L1 < N × B

In addition, when the number of coils in which at least some of the plurality of coils are accommodated in the second region is M, the length (L2) of the second region is characterized by satisfying the following equation 2.

(Formula 2) L2 > M × B

In addition, it is characterized in that the radial center of the first region and the radial center of the second region are aligned on a straight line.

Additionally, the spacing between the plurality of coils is characterized by being equal to or greater than 0.4 times the thickness of one of the plurality of coils and less than 0.5 times the thickness of the other.

In addition, the coil slot further includes a third region provided between the first region and the second region, and when an imaginary straight line extending from one side of the first region is referred to as a first axis and an imaginary straight line extending from one side of a third region that touches one side of the first region is referred to as a second axis, an angle (θ) between the first axis and the second axis is 12 degrees or more and less than 14 degrees, and the second region and the third region are characterized in that the point where they touch each other has a rounded shape.

A motor including a stator assay of the present invention is characterized by including a stator assay having the characteristics of the first clause and a rotor provided in the axial direction of the stator assay.

According to the stator assay and the motor including the stator assay according to the present invention as described above, damage to the insulation that may occur when the coil is inserted into the coil slot is prevented, thereby reducing the defect rate during the stator assay and motor production.

FIG. 1 is a cross-sectional view of a stator assay according to an embodiment of the present invention.
FIG. 2 is an enlarged cross-sectional view of a coil slot of a stator assembly according to an embodiment of the present invention.

The above-described objects, features, and advantages of the present invention will become more apparent through the following examples taken in conjunction with the accompanying drawings. The specific structural and functional descriptions below are merely illustrative for the purpose of explaining embodiments according to the concept of the present invention, and embodiments according to the concept of the present invention may be implemented in various forms and should not be construed as limited to the embodiments described in this specification or application. Since embodiments according to the concept of the present invention may have various modifications and may take various forms, specific embodiments are illustrated in the drawings and described in detail in this specification or application. However, this is not intended to limit embodiments according to the concept of the present invention to specific disclosed forms, but should be understood to include all modifications, equivalents, and substitutes included in the spirit and technical scope of the present invention. Terms such as first and/or second may be used to describe various components, but the components are not limited to the terms. Terms are used solely for the purpose of distinguishing one component from another; for example, a first component may be referred to as a second component, and similarly, a second component may also be referred to as a first component, without departing from the scope of the rights according to the concept of the present invention. When a component is referred to as being connected or coupled to another component, it should be understood that it may be directly connected or coupled to that other component, but there may also be other components in between. Conversely, when a component is referred to as being directly connected or coupled to another component, it should be understood that there are no other components in between. Other expressions used to describe the relationship between components, such as "between," "directly between," "adjacent to," and "directly adjacent to," should also be interpreted similarly. The terminology used herein is merely used to describe specific embodiments and is not intended to limit the present invention. The singular expression "a," "an," and "the" include plural expressions unless the context clearly indicates otherwise. It should be understood that the terms “include” or “have” as used herein are intended to indicate the presence of a described feature, number, step, operation, component, part, or combination thereof, but do not preclude the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof. Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by a person of ordinary skill in the art to which the present invention pertains. Terms defined in commonly used dictionaries should be interpreted as having a meaning consistent with the meaning they have in the context of the related art, and shall not be interpreted in an idealized or overly formal sense unless explicitly defined herein. Hereinafter, the present invention will be described in detail by describing a preferred embodiment of the present invention with reference to the accompanying drawings. The same reference numerals presented in each drawing represent the same elements.

Referring to the attached drawings below, a stator assembly and a motor including a stator assembly according to an embodiment of the present invention will be described in detail.

FIG. 1 shows a cross-sectional view of a stator assay (100) according to one embodiment of the present invention.

As illustrated, a stator assembly (100) according to one embodiment of the present invention is composed of a yoke (110), a tooth (120), a shoe (130), a coil slot (140), and a coil module (150).

The yoke (110) has a cylindrical shape, is made of a soft magnetic material, and includes a hollow portion. A rotor (not shown) can be inserted into the hollow portion.

The teeth (120) are formed in multiple numbers extending in the direction of the central axis of the yoke (110). Meanwhile, the teeth (120) may be made of the same material as the yoke (110).

The shoe (130) is provided at the end of the tooth (120) in the direction of the central axis of the yoke (110). Meanwhile, the shoe (130) may be made of the same material as the yoke (110) and the tooth (120).

A coil slot (140) is provided between a plurality of teeth (120) and is a space formed by adjacent teeth (120). Specifically, the coil slot (140) can be defined as a space between a tooth (120) and another tooth (120) existing in the tangential direction of the yoke. In addition, a coil module (150) formed in a form in which a plurality of coils are stacked can be accommodated in the coil slot (140).

In this way, the yoke (110), teeth (120), shoes (130) and coil slots (140) form one stator.

In addition, the stator assembly (100) includes a coil module (150) along with the stator. The coil module (150) includes a plurality of coils accommodated in the coil slot (140). Specifically, the coil module (150) may have a plurality of coils stacked in the radial direction of the yoke (110) in the coil slot (140), and after inserting the plurality of coils into the coil slot (140), the ends of the coils are joined to form one coil, thereby forming the coil module (150). In one embodiment, one coil constituting the coil module (150) may be a hairpin-shaped coil having a “U” shape. Both legs of the plurality of coils constituting the coil module (150) may each be wrapped with a first insulator (not shown). In one embodiment, the first insulator may be made of an insulating material that serves to insulate between coils, such as insulating paper.

Additionally, a second insulator (not shown) of a different material may be included between the tooth (120) and the coil module (150) in addition to the first insulator of the coil. Specifically, the second insulator is made of a material capable of insulating the coil module (150) and the tooth (120), and may be provided in the space between the coil module (150) and the tooth (120) when the coil module (150) is accommodated in the coil slot (140). In one embodiment, the second insulator may be filled in the space between the coil module (150) and the tooth (120).

In the case of the prior art, when a coil covered with an insulating material is inserted into a rectangular coil slot (140) of a stator, interference occurs with the teeth (120) provided on both sides of the coil slot (140), which damages the insulator and causes defects in the manufacture of the stator assembly (100) and the motor. In order to solve the above problem, the coil slot (140) of the present invention is characterized in that it includes first and second regions (141, 142) that are distinct from each other, and the maximum width (W1) of the first region is wider than the maximum width (W2) of the second region. Specifically, the coil slot (140), which is an internal space formed by a plurality of teeth (120), can be divided into two regions, the first and second regions (141, 142).

Additionally, in order to distinguish the first and second regions (141, 142), the coil slot (140) includes a third region (143) between the first region (141) and the second region (142). The third region (143) will be described later.

Here, the maximum width (W1) of the first region among the first and second regions (141, 142) is set wider than the maximum width (W2) of the second region so that the coil module (150) can be inserted into the coil slot (140) through the first region (141) without being affected by the teeth (120) arranged on both sides of the coil slot (140). In order to prevent interference of the insulator, if the width of the coil slot (140) is formed to be wide overall without distinction between the first region (141) and the second region (142), the corresponding space must be filled with the second insulator, which may increase the material cost and increase the weight of the stator. In addition, as the teeth (120) become thinner, the magnetic flux resistance increases, which increases the possibility of magnetic saturation, and accordingly, the leakage flux further increases as the width of the coil slot (140) increases.

In conclusion, due to the above-mentioned problems, the maximum width (W1) of the first region, which is a part of the coil slot (140), is made wider than the maximum width (W2) of the second region, which has the effect of preventing damage to the insulation while minimizing the impact on the performance of the motor. Specific values such as the maximum width (W1, W2) and length (L1, L2) of the first and second regions (141, 142) will be described later.

In addition, the first region (141) is characterized in that it is provided in a region further from the central axis of the yoke (110) than the second region (142). Specifically, the distance at which the first region (141) is spaced from the central axis of the yoke (110) is characterized in that it is greater than the distance at which the second region (142) is spaced from the central axis of the yoke (110).

Referring to FIG. 2, which illustrates an embodiment of the present invention, the first region (141) is disposed at a greater distance from the central axis of the yoke (110) than the second region (142). This is because the width of the teeth (120) increases in the radial direction from the central axis of the yoke (110), thereby securing a space for forming the first region (141). In addition, when the first region (141) is disposed (120) at a closer distance from the central axis of the yoke (110), the teeth (120) become narrow, which increases the magnetic resistance and increases the possibility of magnetic saturation, which may reduce the performance of the motor.

In conclusion, when the first region (141) is formed at a distance further from the central axis of the yoke (110) than the second region (142), the problem of the width of the tooth (120) becoming thin can be prevented, and damage to the insulation can be prevented while minimizing the impact on the performance of the motor.

In another embodiment for specifying the first region (141) and the second region (142), the first region (141) and the second region (142) may be located outside a predetermined radius with the central axis of the yoke (110) as the origin, and the second region (142) may be located within a predetermined radius. Here, the predetermined radius is characterized in that it is larger than the length (L2) of the second region.

In conclusion, the positions where the first region (141) and the second region (142) are formed can be specified based on the central axis of the yoke (110), but the positions where the first region (141) and the second region (142) are formed can be specified based on a predetermined radius with the central axis of the yoke (110) as the origin.

In Fig. 2, an enlarged cross-sectional view of the coil slot (140) of the stator assembly (100) is shown.

To describe the maximum width and length of the first and second regions (141, 142) as illustrated and the width and thickness of one of the plurality of coils, the terms are defined as follows.

The maximum width (W1, W2) of the first and second regions refers to the length formed in the tangential direction of the yoke in the first and second regions (141, 142). In addition, the length (L1, L2) of the first and second regions refers to the length formed in the radial direction of the yoke in the first and second regions (141, 142). In addition, the width (A) of the coil refers to the length in the tangential direction of the yoke in one of the plurality of coils included in the coil module (150). In addition, the thickness (B) of the coil refers to the length in the radial direction of the yoke in one of the plurality of coils included in the coil module (150).

Below, the maximum widths (W1, W2) of the first and second regions (141, 142) are described. As described above, the maximum width (W1) of the first region is characterized by being wider than the maximum width (W2) of the second region.

First, in the relationship between the first region (141) and the second region (142), the maximum width (W1) of the first region is characterized by being equal to or greater than 1.05 times and less than 1.25 times the maximum width (W2) of the second region. In one embodiment, the maximum width (W1) of the first region may be 1.15 times greater than the maximum width (W2) of the second region. This is because, if the maximum width (W1) of the first region is formed wider than necessary, the magnetic flux resistance increases as the width of the tooth (120) decreases, and the possibility of magnetic flux saturation increases, which may affect the performance of the motor.

Next, in the relationship between the first region (141) and the coil, the maximum width (W1) of the first region is characterized by being equal to or greater than 1.4 times and less than 1.6 times the width (A) of the coil. In one embodiment, the maximum width (W1) of the first region may be 1.5 times greater than the width (A) of the coil. This is because, since the coil will be inserted into the first region (141), it is necessary to select the maximum width (W1) of the first region by taking into consideration the width (A) of the coil in order to reduce interference with the insulator attached to the coil.

Next, in the relationship between the second region (142) and the width (A) of the coil, the maximum width (W2) of the second region is characterized by being equal to or greater than 1.2 times the width (A) of the coil and smaller than the maximum width (W1) of the first region. In one embodiment, the maximum width (W2) of the second region may be 1.3 times greater than the width (A) of the coil. This is because the coil must be settled in the second region (142), and therefore must be wider than the width (A) of the coil, and in order to minimize the impact on the performance of the motor, the maximum width (W2) of the second region cannot be formed larger than the maximum width (W1) of the first region.

In conclusion, as described above, by forming the maximum width (W1, W2) of the first and second regions, there is an effect of preventing damage to the insulation of the coil while minimizing the impact on the performance of the motor.

Below, the lengths of the first and second areas (141, 142) are described.

The length (L1) of the first region is characterized by being shorter than the length (L2) of the second region. This is because, if the length (L1) of the first region is formed longer than necessary, the width of the tooth (120) decreases, increasing the possibility of magnetic flux resistance and magnetic saturation, and accordingly, increasing the width of the coil slot (140), increasing the leakage flux. Therefore, by forming the length (L1) of the first region to a minimum length, the possibility of damage to the insulation can be greatly reduced while minimizing the impact on the performance of the motor.

First, in the case of the length (L1) of the first region, the thicknesses (B) of the plurality of coils included in the coil module (150) are all the same, and when the number of coils in which at least some of the plurality of coils are accommodated in the first region (141) is N, the length (L1) of the first region is characterized by satisfying the following equation 1.

(Formula 1) L1 < N × B

As an example, FIG. 2 illustrates a case where at least some of the plurality of coils of the coil module (150) are accommodated in the first region (141) and the number of coils is three, and the length (L1) of the first region is smaller than 3 × B, which is the thickness of three coils. As described above, since there is a high concern that the width of the teeth (120) will be reduced and affect the performance of the motor, it is necessary to appropriately select the number of coils that can be introduced into the first region (141) to set the length (L1) of the first region.

Next, in the case of the length (L2) of the second region, when the number of coils in which at least some of the plurality of coils are accommodated in the second region (142) is M, the length (L2) of the second region is characterized by satisfying the following equation 2.

(Formula 2) L2 > M × B

As an example, FIG. 2 illustrates a case where at least some of the plurality of coils of the coil module (150) are accommodated in the second region (142) and the number of coils is 5, and the length (L2) of the second region is greater than 5 × B, which is the thickness of 5 coils. This is because the length (L2) of the second region is determined according to the number of coils accommodated in the second region (142), so it is necessary to select an appropriate number of coils.

Meanwhile, the spacing between the plurality of coils of the coil module (150) inserted into the first region (141) and the second region (142) is characterized by being equal to or greater than 0.4 times and less than 0.5 times the thickness (B) of one of the plurality of coils. This is to prevent damage to the insulation due to contact between coils, as an insulation exists between the plurality of coils.

Next, the relationship between the first area (141) and the second area (142) will be described.

The radial center of the first region (141) of the coil slot (140) and the radial center of the second region (142) are characterized by being aligned on a straight line. Specifically, this means that the radial center of the first region (141), which is parallel to the radial direction from the central axis of the yoke (110), and the radial center of the second region (142), which is parallel to the radial direction from the central axis of the yoke (110), are aligned on the same line. Accordingly, the first region (141) and the second region (142) can be symmetrical with respect to the radial center, and a plurality of teeth (120) included in the stator assembly (100) can have the same shape.

In addition, the coil slot (140) further includes a third region (143) provided between the first region (141) and the second region (142). Specifically, the third region (143) is located between the first region (141) and the second region (142) and includes a feature of connecting the first region (141) and the second region (142). This is because the maximum width (W1) of the first region and the maximum width (W2) of the second region are different, so it is necessary to connect the two regions with different widths to form the coil slot (140). In one embodiment, the third region (143) may connect the first region (141) and the second region (142) in a tapered shape.

Looking specifically at the third region (143), when an imaginary straight line extending from one side of the first region (141) is referred to as a first axis (161), and an imaginary straight line extending from one side of the third region (143) that touches one side of the first region (141) is referred to as a second axis (162), the angle (θ) between the first axis (161) and the second axis (162) is characterized by being 12 degrees or more and less than 14 degrees. This is because, when the angle (θ) between the first axis (161) and the second axis (162) increases, the point where the second region (142) and the third region (143) come into contact with each other protrudes, which increases the possibility of damaging the insulation of the coil received in the first region (141). Therefore, the angle (θ) between the first axis (161) and the second axis (162) is limited to 12 degrees or more and less than 14 degrees.

In order to further prevent damage to the insulation of the coil, the present invention is characterized in that the second region (142) and the third region (143) have a rounded shape at the point where they come into contact with each other. Specifically, the point where the two ends of the yoke (110) side of the second region (142) and the third region (143) come into contact with each other has a rounded shape with a predetermined curvature. This is to reduce the possibility that the insulation of the coil, when accommodated in the first region (141) moves to the second region (142), will be damaged by the point where the second region (142) and the third region (143) come into contact with each other.

Next, a motor including the stator assembly (100) of the present invention will be described. The motor may be characterized by including a stator assembly (100) having the characteristics of the first clause and a rotor (not shown) provided in the axial direction of the stator assembly (100). In one embodiment, the motor may be a motor including a coil having a hairpin shape in a coil module (150).

In conclusion, by applying the stator assay (100) having the characteristics of the first clause to a motor, a motor can be produced with a lower defect rate than the prior art while minimizing the impact on the performance of the motor.

The technical concept of the present invention should not be construed solely based on the above-described embodiments. The scope of application is diverse, and various modifications and variations are possible within the scope of those skilled in the art without departing from the spirit of the invention as claimed in the claims. Therefore, such improvements and modifications, as long as they are obvious to those skilled in the art, fall within the scope of protection of the present invention.

100: Stator Assay
110: York
120 : Chi
130: Shu
140: Coil slot
141: Area 1
142: Second Area
143: Third Area
150: Coil module
161: First axis
162: Second axis
L1: Length of the first region
L2: Length of the second region
W1: Maximum width of area 1
W2: Maximum width of the second area
A: Coil width
B: Coil thickness

Claims (12)

A cylindrical yoke containing a soft magnetic material;
A plurality of teeth formed extending in the direction of the central axis of the yoke;
A shoe provided at the end of the tooth in the direction of the central axis of the yoke;
A coil slot is a space formed by adjacent teeth and provided between the plurality of teeth; and
A coil module comprising a plurality of coils accommodated in the coil slots,
The above coil slot comprises first and second distinct regions,
The maximum width of the first region is wider than the maximum width of the second region,
The above coil slot is
Further comprising a third region provided between the first region and the second region,
When an imaginary straight line extending from one side of the first region is called the first axis, and an imaginary straight line extending from one side of the third region that touches one side of the first region is called the second axis,
The angle (θ) between the first axis and the second axis is 12 degrees or more and less than 14 degrees,
The second region and the third region have a rounded shape at the point where they touch each other.
Stator assay featuring .
In the first paragraph,
The first region is provided in a region further from the center axis of the yoke than the second region.
Stator assay featuring .
In the first paragraph,
The maximum width of the first region is equal to or greater than 1.05 times and less than 1.25 times the maximum width of the second region.
Stator assay featuring .
In the first paragraph,
The maximum width of the first region is 1.4 times or more and less than 1.6 times the width of the coil.
Stator assay featuring .
In the first paragraph,
The maximum width of the second region is 1.2 times or more greater than the width of the coil and less than the maximum width of the first region.
Stator assay featuring .
In the first paragraph,
The length of the first region is shorter than the length of the second region
Stator assay featuring .
In the first paragraph,
The thickness (B) of the plurality of coils included in the above coil module is all the same,
When the number of coils in which at least some of the above plurality of coils are accommodated in the first region is N,
The length (L1) of the first region above satisfies the following formula 1.
Stator assay featuring .
(Formula 1) L1 < N × B
In paragraph 7,
When the number of coils in which at least some of the above plurality of coils are accommodated in the second region is M,
The length (L2) of the second region above satisfies the following formula 2.
Stator assay featuring .
(Formula 2) L2 > M × B
In the first paragraph.
The radial center of the first region and the radial center of the second region are aligned on a straight line.
Stator assay featuring .
In the first paragraph.
The spacing between the plurality of coils is greater than or equal to 0.4 times the thickness of one of the plurality of coils and less than 0.5 times the thickness of the other.
Stator assay featuring .
delete Stator assay having the characteristics of the first clause;
A rotor provided in the axial direction of the above stator assembly;
A motor featuring .